Stringer crawler

ABSTRACT

A self-contained crawler assembly is engageable to a stringer and is adapted to position a drill bushing along the stringer for performing machining operations. The crawler assembly includes a longitudinal slider, a lateral slider and a controller for regulating operation of the longitudinal and lateral sliders for positioning the drill bushing at a hole location. In a further embodiment, the crawler assembly may include a longitudinal friction drive which is directly engageable to the stringer and which is operative to move in a direction parallel to the stringer.

CROSS-REFERENCE TO RELATED APPLICATIONS

(Not Applicable)

STATEMENT RE: FEDERALLY SPONSORED RESEARCH/DEVELOPMENT

(Not Applicable)

FIELD

The present disclosure relates generally to drilling fixtures and, moreparticularly, to a crawler assembly that is engageable to a stringer fordrilling a pattern of holes.

BACKGROUND

In the production of various assemblies, a large quantity of fastenerholes are typically drilled in mating parts in order to facilitatemechanical attachment of the various components. For example, duringaircraft assembly operations, wing skin panels may be mechanicallyfastened to substructure such as stiffeners and stringers. Holes must bedrilled at spaced intervals along the joint between the stringer and thepanel to allow installation of the mechanical fasteners.

The drilling of such fastener holes must typically be performed with ahigh degree of precision with respect to locational tolerances of theholes as well as with respect to hole orientation and hole size. Becauseof the relatively high degree of precision required for such fastenerholes, it is typically the practice to drill such holes using analignment tool or assembly fixture. Conventional alignment tools orassembly fixtures typically includes a plurality of drill bushingslocated at spaced intervals along a hole pattern. The drill bushingsmaintain alignment of a drill motor that is used to drill each of theholes in the hole pattern.

In an aircraft assembly production line, various assembly fixtures areused during the overall assembly of each production unit. For example,during wing assembly, assembly tools may be used to performmanufacturing operations on the wing skin panels and substructure. Inany production line, it is typically desirable to improve productionflow and reduce overall assembly time.

One way in which assembly time can be reduced in a production line is toperform certain operations in parallel with one another instead ofperforming all operations in sequence. Another way to improve productionflow is to move certain operations off of main assembly tools to reducethe amount of time that each assembly tool is occupied by eachproduction unit. As applied to operations involving the drilling offastener holes, it may be desirable to perform certain drillingoperations off of the main assembly tool thereby freeing the mainassembly tool for other operations and avoiding time-consuming setup fordrilling holes using a conventional drill jig or alignment tool.

As can be seen, there exists a need in the art for a system and methodfor drilling fastener holes in an assembly which improves overallproduction flow. Furthermore, there exists a need in the art for asystem and method for drilling fastener holes in an assembly which canincrease part flow and which is low in cost, simple in construction andeasy to use.

SUMMARY

The above-described needs associated with drilling hole patterns isspecifically addressed and alleviated by the embodiments disclosedherein. More specifically, provided is a self-contained crawler assemblywhich may be engageable to a stringer for positioning the crawlerassembly therealong. The crawler assembly may be configured as aportable and/or battery-powered automated positioning device forpositioning a drill bushing for use with a drill motor or automateddrilling system at a plurality of predetermined hole locations of a holepattern. The crawler assembly is specifically adapted for positioningthe drill bushing at the predetermined hole locations with a high degreeof positional and orientational accuracy such that a series of holes maybe drilled in the stringer and/or in a panel to which the stringer maybe fastened.

In one embodiment, the crawler assembly may be adapted to drill fastenerholes though structure. For example, the crawler assembly may be adaptedto drill disbond fastener holes or system bracket holes along a bondjoint between stiffeners that may be bonded to wing skin panels. Thecrawler assembly may be adapted to engage or mount to the stringerand/or stiffener and may use various reference features such aspre-drilled holes (i.e., index holes), surface features (i.e., stringeror panel surfaces and edges) or other geometrical features for indexingthe hole pattern. The crawler assembly may index to the referencefeature and may be sequentially driven to any number of predeterminedhole locations in a hole pattern by means of a computer numericalcontrol (CNC) file and/or via hole pattern information otherwiseprovided to the crawler assembly (e.g., manually entered).

The technical effects of the disclosure include an improvement in holelocational accuracy, a reduction in cost and time conventionallyassociated with drilling holes in an assembly, and an increase inutilization of tooling fixtures that may be intended for other purposes.Furthermore, the crawler assembly may improve part flow in a productionline by eliminating the need to use tooling that may otherwise be usedfor manufacturing operations. In addition, the crawler assemblyfacilitates the drilling of fastener holes without the need fortime-consuming setup on a drill jig or fixture. In this regard, thecrawler assembly may be used while the composite assembly is supportedin a simple part-holding fixture or a transportation fixture such as apickup stand.

In one embodiment, the crawler assembly may comprise an elongateattachment mechanism such as a rail preferably constructed of relativelystiff or rigid material. The attachment mechanism may be specificallyadapted to be removably attachable to the stringer such as via a pair ofclamping devices disposable along a length of the attachment mechanismsuch as at opposing ends of the attachment mechanism.

The crawler assembly may further include a longitudinal slider and alateral slider. The longitudinal slider may be engageable to theattachment mechanism such as the rail and may be movable along adirection that is parallel to a longitudinal axis of the stringer via adrive mechanism (e.g., electric motor) mounted to the attachmentmechanism (i.e., rail). The lateral slider may be configured to bemountable to the longitudinal slider and may be adapted to be movable ina direction that is perpendicular to the longitudinal axis of thestringer. In this regard, the longitudinal and lateral sliders aredriven along their respective directions to sequentially position thedrill bushing to at least one of a plurality of predetermined holelocations in a hole pattern.

In one embodiment, the longitudinal slider may include a normalizingmechanism which may establish and maintain a desired orientation of thecrawler assembly relative to the stringer. For example, the normalizingmechanism may maintain a perpendicular orientation of the drill bushingrelative to the stringer. In this regard, the normalizing mechanism maycomprise an opposing pair of spring-loaded stringer rollers which may bedisposed on opposing sides of a vertical web of the stringer and whichmay be biased thereagainst by means of compression springs or othersuitable biasing mechanisms.

Although the stringer is described as having a vertical web, it shouldbe noted that the vertical web may be provided in non-perpendicularrelation to the stinger. More specifically, the vertical web of thestringer may be provided in any angular orientation and is further notlimited to a planar or flat vertical web but may take non-planarcross-sectional shapes including curved shapes and complex angledshapes. Likewise, the various components that make up the crawlerassembly (e.g., the normalizing mechanism, the clamping devices, theattachment mechanism or rail) are preferably configured to becomplementary to the stringer to facilitate operation thereupon.

Each of the lateral and longitudinal sliders may preferably include thedrive mechanism which, as was indicated above, may be an electric motorfor moving the longitudinal and lateral sliders along their respectivedirections. The drive mechanisms may be operatively coupled to thelongitudinal and lateral sliders by any suitable drive trainconfiguration including, but not limited to, a rack and pinion drivetrain.

The drive train may include a rack disposable along a length of the railand may comprise a series of gear teeth disposed linearly therealong.The pinion may comprise a cylindrical gear having teeth disposedcircumferentially therearound and which are sized and configuredcomplementary to the gear teeth formed along the rack. In oneembodiment, the pinion may be configured to be disengagable from therack such that the longitudinal slider and the lateral slider may eachbe selectively moved by manual repositioning to any desired location.

Toward this end, the longitudinal slider and lateral slider may eachinclude a biasing mechanism such as a spring-loaded mechanism to biasthe motor into and out of engagement with the motor drive train. Each ofthe drive mechanisms (i.e., motors) may be pivotably mounted torespective ones of the longitudinal and/or lateral sliders to facilitatemanual disengagement thereof via a pivot arm.

The crawler assembly may optionally include a brake mechanism forbraking the longitudinal and/or lateral sliders against movement inorder to stop the drill bushing at the predetermined hole location. Thebrake mechanism for each of the longitudinal and lateral sliders maycomprise at least one electromagnet which may be configured tomagnetically engage a stationary metallic component such as theattachment mechanism (i.e., rail) and/or the lateral or longitudinalslider. Optionally, the brake mechanism may comprise a simplespring-loaded brake.

The crawler assembly may further include a controller which may beprogrammable with at least one hole pattern comprising a plurality ofpredetermined hole locations. The controller is operative to cause thedrive and brake mechanisms to cooperate in moving the drill bushingtoward the predetermined hole locations of the hole pattern and to stopthe drill bushing upon arrival thereat.

Advantageously, the controller may include an operator interface tofacilitate real-time programming of the crawler assembly via a keyboard,a touch screen, a keypad, pushbuttons or other suitable interfacemechanisms. The controller may be operative to facilitate manualprogramming with a new hole pattern and allow for manual entry ofcoordinates of predetermined hole locations. The crawler assembly mayoptionally include positional feedback mechanisms such as linearencoders or rotary encoders which may be communicatively coupled to thecontroller to indicate the position of the drill bushing relative to anindex feature and/or relative to the hole pattern.

In an alternative embodiment of the crawler assembly, a longitudinalfriction drive may be provided to engage the stringer such as at anupper flange thereof. In this regard, the attachment mechanism (i.e.,rail) as used in the above-described crawler assembly may be omitted.The crawler assembly with the a longitudinal friction drive may befrictionally engaged directly to the stringer such that the drillbushing is movable therealong by at least one or more drive rollersplaced in rolling engagement with the stringer along an upper flange ofthe stringer. A rotary encoder may be communicatively coupled to thecontroller and preferably is operable independent of the drive rollersin order to maintain accuracy in positioning the drill bushing in thecase of slippage of the drive roller.

The longitudinal friction drive may further include at least one and,more preferably, a pair of clamping devices disposed on opposing ends ofthe crawler assembly. Each one of the clamping devices may be engageableto the stringer via a plurality of stringer rollers. The stringer rollermay be placed in rolling contact against an inner surface of the upperflange of the stringer and may be positioned opposite the driveroller(s). In addition, a portion of the stringer rollers may bedisposable in bearing contact against opposing sides of the vertical webof the stringer to provide a normalizing mechanism to the longitudinalfriction drive crawler assembly.

The clamping devices in combination with the drive rollers facilitatesclamping of the crawler assembly to the vertical web and/or to the upperflange of the stringer. When the clamping devices are clamped, thestringer rollers are placed in bearing contact against the opposingsides of the vertical web to provide a normalizing feature to maintainthe crawler assembly in a normal or perpendicular orientation relativeto the stringer. The stringer rollers are also placed in bearing contactagainst the inner surface of the upper flange to maintain the driveroller in close contact with the stringer for frictional driving of thecrawler assembly.

The friction drive crawler assembly preferably includes a controllerhaving a microprocessor and other suitable electronic components such asan operator interface in order to effectuate movement of thelongitudinal slider and lateral slider. The controller iscommunicatively coupled to the respective drive mechanisms and/or brakemechanisms and cause the drive mechanisms to move the drill bushingtoward at least one of the predetermined hole locations and stop thedrill bushing upon arrival thereat using the brake mechanism, ifprovided. However, for configurations where the drive wheel is directlycoupled to the drive mechanism (i.e., coupled to the motor), the brakemechanism may be unnecessary for the longitudinal friction drive crawlerconfiguration because the drive mechanism may be operative to provideboth driving and braking forces to the drive roller.

The features, functions and advantages that have been discussed can beachieved independently in various embodiments of the present disclosureor may be combined in yet other embodiments, further details of whichcan be seen with reference to the following description and drawingsbelow.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features of the present disclosure will become moreapparent upon reference to the drawings wherein like numbers refer tolike parts throughout and wherein:

FIG. 1 is a perspective view of a crawler assembly which may beengageable to a stringer;

FIG. 2 is a perspective view of the crawler assembly illustrating anattachment mechanism which is removably attachable to the stringer;

FIG. 3 is a perspective view of the crawler assembly wherein theattachment mechanism is repositioned relative to that which is shown inFIG. 2;

FIG. 4 is a plan view of the crawler assembly and attachment mechanismengaged to the stringer;

FIG. 5 is a view taken along lines 5-5 of FIG. 4 illustrating a sideview of the crawler assembly and attachment mechanism engaged to thestringer;

FIG. 6 is a view taken along lines 6-6 of FIG. 4 and illustrating a sideview of the crawler assembly and attachment mechanism engaged to thestringer;

FIG. 7 is a cross-sectional illustration taken along lines 7-7 of FIG. 4and illustrating a clamping device adapted for mounting the attachmentmechanism to the stringer;

FIG. 8 is a cross-sectional view taken along lines 8-8 of FIG. 4 andillustrating a normalizing mechanism comprising a pair of stringerrollers engaged to opposite sides of a vertical web of the stringer;

FIG. 9 is a cross-sectional illustration taken along lines 9-9 of FIG. 4and illustrating the interconnection of the lateral slider to thelongitudinal slider at a base thereof;

FIG. 10 is a cross-sectional illustration taken along lines 10-10 ofFigure 4 and illustrating a drive mechanism or motor engaged to thelateral slider;

FIG. 11 is a perspective illustration of the crawler assembly taken froma lower side thereof;

FIG. 12A is a perspective illustration of the crawler assembly in analternative embodiment disposed in spaced relation to a stringer;

FIG. 12B is a perspective illustration of an electronic module of thecrawler assembly in an alternative embodiment disposed in spacedrelation to a longitudinal and lateral slider of the crawler assembly;

FIG. 13 is a perspective illustration of the electronic module disposedin spaced relation to the longitudinal and lateral sliders;

FIG. 14A is a perspective illustration of the crawler assembly engagedto the stringer;

FIG. 14B is a perspective illustration of the lateral slider in analternative embodiment;

FIG. 15 is a top view of the crawler assembly engaged to the stringer;

FIG. 16 is a side view of the crawler engaged to the stringer;

FIG. 17 is a cross-sectional view taken along lines 17-17 of FIG. 16 andillustrating a drive wheel of the electronics module frictionallyengaged to the stringer;

FIG. 18 is a sectional illustration taken along lines 18-18 of FIG. 16and illustrating a clamping device engaged to the stringer;

FIG. 19 is a side sectional illustration taken along lines 19-19 of FIG.17 and illustrating a plurality of rollers on opposed sides of thevertical web;

FIG. 20 is a side sectional illustration taken along lines 20-20 of FIG.17 and illustrating a pair of drive rollers in opposing relation to therollers of the clamping device;

FIG. 21 is an exploded illustration of the electronics module;

FIG. 22 is an exploded illustration of the electronics module viewedfrom an upper side thereof;

FIG. 23 is a flow diagram of an aircraft production and servicemethodology; and

FIG. 24 is a block diagram of an aircraft.

DETAILED DESCRIPTION

Referring now to the drawings wherein the showings are for purposes ofillustrating preferred and various embodiments of the disclosure onlyand not for purposes of limiting the same, FIGS. 1-11 illustrate acrawler assembly 10 in one embodiment wherein the crawler assembly 10 isengageable to a stringer 12 using an elongate attachment mechanism 28such as a rigid rail 30 which is removably attachable to the stringer12. The crawler assembly 10 illustrated in FIGS. 1-11 may include alongitudinal slider 60 and a lateral slider 74. The longitudinal slider60 may be engageable to the attachment mechanism 28. The lateral slider74 may be engageable to the longitudinal slider 60. The longitudinalslider 60 and lateral slider 74 are movable along the attachmentmechanism 28 for positioning a drill bushing 102 or automated drillingsystem (not shown) to at least one predetermined hole location 192 of ahole pattern 190 such that a hole may be drilled through the stringer 12and/or through a panel 26 or other member that may be attached to thestringer 12.

FIGS. 12A-22 illustrate a crawler assembly 10 in a further embodimenthaving a longitudinal friction drive 176 for engaging the stringer 12.As opposed to the embodiment illustrated in FIGS. 1-11 wherein thelongitudinal slider 60 is mounted to the attachment mechanism 28, thelongitudinal friction drive 176 of the embodiment illustrated in FIGS.12-22 is directly mounted to the stringer 12 and is frictionally driventherealong.

The longitudinal friction drive 176 cooperates with the lateral slider74 to move the drill bushing 102 or automated drilling system to one ormore predetermined hole locations 192 of the hole pattern 190. Theautomated drilling system may comprise an air motor (e.g., drill motor)or other suitable device mounted on the crawler assembly 10 and beingadapted to drill a hole at the predetermined hole locations 192 whenpositioned thereat by the stringer crawler in a completely autonomousprocess.

Each of the embodiments illustrated in FIGS. 1-11 and in FIGS. 12A-22comprise a two-axis hole location system which attaches to the upperflange 16 of the stringer 12. As can be seen, the stringer 12 may beconfigured as an I-shaped beam. However, the stringer 12 may be providedin any configuration, size and shape.

The crawler assembly 10 may be provided as a self-contained automateddrill bushing 102 positioner preferably, but optionally, having its ownpower source 146 such as a battery. In one embodiment, the crawlerassembly 10 may be adapted for drilling fastener holes in any assemblyhaving a stringer such as a stringer/wing panel assembly. However, thecrawler assembly 10 as disclosed herein may be utilized for performing awide variety of machining operations and is not limited to locating adrill bushing 102 along a stringer/panel assembly. For example, thecrawler assembly 10 may be used for drilling fastener holes in any typeof metallic or nonmetallic structure. Furthermore, the crawler assembly10 is not limited to locating the drill bushing 102 relative to astringer 12 and panel 26 assembly but may also be used for locating thedrill bushing 102 along a single component such as along the stringer 12itself or along other components where a hole pattern 190 is desired.

Advantageously, the crawler assembly 10 as disclosed herein may usevarious reference features 194 such as pre-drilled index holes 196 orusing various surface features of the stringer 12 and/or panel 26 as astarting point for positioning the drill bushing. As was mentioned, suchreference features 194 may include pre-drilled holes that may be drilledin upstream processes and/or the reference features 194 may comprisevarious features of the stringer 12 itself including, but not limitedto, various edges, sides, surfaces and other features of the stringer 12and/or panel 26.

The stringer 12 may comprise lower and upper flanges 18, 16interconnected by a vertical web 20 formed in an “I” shape. The upperflange 16 may include inner and outer surfaces 22, 24 wherein the innersurface 22 is located adjacent the vertical web 20 and the outer surface24 is opposite the inner surface 22. The crawler assembly 10 may beconfigured to move the drill bushing 102 by indexing from a referencefeature 194 such as the inner surface 22 of the upper flange 16 or froman index hole 196 that may be pre-drilled in the stringer 12 and/orpanel 26.

The crawler assembly 10 may index (i.e., reposition the drill bushing)from the reference feature 194 in order to sequentially move the drillbushing 102 to a set of predetermined hole locations 192 that comprisethe hole pattern 190. The hole pattern 190 may be provided as part of acomputer numerical control (CNC) file for driving the crawler assembly10 to predetermined hole locations 192 that make up the hole pattern190. The crawler assembly 10 illustrated in FIGS. 1-11 utilizes therigid attachment mechanism 28 (i.e., drive rail 30) while the crawlerassembly 10 illustrated in FIGS. 12A-22 utilizes a friction drive inorder to drive the drill bushing 102 to any one of a plurality ofpredetermined hole locations 192 of the hole pattern 190.

Referring more particularly now to FIGS. 1-11, shown is the crawlerassembly 10 embodiment which is engageable to the stringer 12 via theattachment mechanism 28. As can be seen in FIG. 1, the crawler assembly10 may include the attachment mechanism 28 which is removably attachableto the stringer 12 using at least one and, more preferably, a pair ofclamping devices 40 which may be positionable at various locations alongthe attachment mechanism 28. The attachment mechanism 28 is adapted tobe clamped to the stringer 12 such as to the upper flange 16 thereof.The crawler assembly 10 further comprises the longitudinal slider 60 anda lateral slider 74.

The longitudinal slider 60 is engageable to the attachment mechanism 28and is movable along a direction parallel to the longitudinal axis 14 ofthe stringer 12. The lateral slider 74 may be mountable to thelongitudinal slider 60 and is preferably movable in a directionperpendicular to the longitudinal axis 14. The lateral slider 74 mayhave a drill bushing 102 mounted thereon to facilitate the formation ofholes through the stringer 12 and/or panel 26 using a tool such as adrill motor 104 as illustrated in FIG. 11.

However, it should be noted that the drill bushing 102 may be adaptedfor performing a variety of alternative machining operations other thandrilling holes in the stringer 12 and/or panel 26. For example, thecrawler assembly 10 as disclosed herein is adapted for positioningdevices other than the drill bushing 102 and which may be provided in avariety of shapes, sizes, and configurations and which may be adaptedfor performing any number of machining operations or non-machiningoperations and is not solely limited to the drilling of holes accordingto a predetermined hole pattern 190.

Referring still to FIGS. 1-11, the crawler assembly 10 may furtherinclude a normalizing mechanism 106 which may maintain a desired orpredetermined orientation of the crawler assembly 10 relative to thestringer 12. For example, the normalizing mechanism 106 may be adaptedto maintain a normal or perpendicular orientation of the drill bushing102 relative to the stringer 12 and/or panel 26. In one embodimentillustrated in FIG. 8, the normalizing mechanism 106 may comprise anopposing pair of stringer rollers 108 disposed on opposing sides of thevertical web 20 of the stringer 12.

Each one of the stringer rollers 108 of the normalizing mechanism 106may be mounted to the longitudinal and/or lateral slider 60, 74 via aroller bracket 110. One or more of the roller brackets 110 may include abiasing mechanism 112 such as a compression spring disposed with theroller bracket 110 in order to provide a biasing force of the stringerroller 108 against opposing sides of the vertical web 20. In thismanner, the normalizing mechanism 106 maintains a desired orientation ofthe crawler assembly 10 with respect to the vertical web 20 of thestringer 12.

In this regard, it should also be noted that the stringer 12 is notlimited to the configuration shown in FIGS. 1-11 as was indicated above.For example, the stringer 12 may be provided in a variety of alternativeshapes, sizes and cross-sections. For example, the stringer 12 may beprovided in a “Z”-shaped cross-section, a hat-shaped cross-section, a“U”-shaped cross-section or any other variety of cross-sectional shapes.Furthermore, the vertical web 20 interconnecting a lower flange 18 ofthe stringer 12 to the upper flange 16 thereof may be disposed in anon-vertical orientation relative to the upper and lower flanges 16, 18.

For example, the vertical web 20 may be provided in an angled (i.e.,non-perpendicular) orientation relative to the panel 26. The normalizingmechanism 106 may be configured to be complementary to the particularshape, size and configuration of the stringer 12 in order to facilitatea desired orientation of the drill bushing 102 relative to the panel 26.In this manner, drilling or other operations may be performed on thestringer 12 and/or panel 26 at any desired orientation.

In one embodiment shown in FIG. 8, the normalizing mechanism 106 may beprovided as a pair of stringer rollers 108 disposed on opposing sides ofthe vertical web 20 of the stringer 12. The stringer rollers 108 may bemounted adjacent to a base 68 of the longitudinal slider 60. However, itis contemplated that the normalizing mechanism 106 may be provided inalternative configurations and is not limited to the orientations andpositions shown in FIG. 8. In this regard, the stringer rollers 108 maybe positioned at any location relative to the stringer 12 or any otherfeature which may provide a normalizing capability to the crawlerassembly 10.

Referring particularly to FIG. 1, shown is the crawler assembly 10disposed in spaced relation to the stringer 12. The elongate attachmentmechanism 28 is removably attachable to the stringer 12 using at leastone and, more preferably, a pair of clamping devices 40 which are shownin FIG. 1 as being disposed in spaced relation to one another along theattachment mechanism 28. Each of the clamping devices 40 is selectivelypositionable at desired locations along a length of the attachmentmechanism 28 via a fastener 48 such as a thumb screw which engages anyone of a plurality of bores 32 formed in the attachment mechanism 28 asbest seen in FIGS. 1 and 2.

Referring briefly to FIG. 7, shown is the clamping device 40 incross-section illustrating an opposing pair of clamp levers 42, each ofwhich may be operatively coupled to a clamp arm 46 configured to engagethe stringer 12 such as along an inner surface 22 of the upper flange16. The clamp levers 42 may be operatively coupled attached to a clampbody 44 as shown in FIG. 7 and, in turn, may be operatively coupled tothe clamp arms 46 such as by a pair of cam-shaped links that allow theclamping device 40 to lock into place when the clamp levers 42 areactuated or pivoted downwardly. Advantageously, the clamping devices 40may be positioned at any location along the rail 30 wherever thereexists a bore 32. Such configuration facilitates positioning theattachment mechanism 28 along the stringer 12 until an ideal locationfor the clamping devices 40 is found.

Referring to FIGS. 2 and 3, shown is the elongate attachment mechanism28 clamped to the stringer 12 via the clamping devices 40 which areshown mounted on opposing ends of the attachment mechanism 28. Whenmounted to the stringer 12 via the attachment mechanism 28, the crawlerassembly 10 as shown in FIG. 2 may facilitate drilling of the holesthrough the lower flange 18 of the stringer 12 and into the panel 26.Alternatively, the crawler assembly 10 may be configured to facilitatethe drilling of holes through the vertical web 20 via an appropriatemounting configuration of the drill bushing 102.

Referring to FIG. 3, shown is the crawler assembly 10 wherein theattachment mechanism 28 has been repositioned toward the right along thestringer 12 in order to facilitate the drilling of an additional numberof holes of a predetermined hole pattern 190. To allow drilling of aremaining number of holes in the series of the predetermined holepattern 190, one of the clamping devices 40 in FIG. 3 has been relocatedto an opposite side of the crawler assembly 10 compared to the positionof the clamping device 40 in FIG. 2 such that in FIG. 3, both clampingdevices 40 are installed on the same side of the attachment mechanism28.

In the arrangement shown in FIG. 3, the crawler assembly 10 may move inan essentially unrestricted manner toward the end of the stringer 12 toallow for completion of the drilling of the holes through the stringer12 and panel 26. The holes may be drilled through the panel 26 and/orstringer 12 in any pattern and are not limited to the linear series ofholes shown in FIGS. 2 and 3. Furthermore, the crawler assembly 10 isnot limited to installation of holes on both sides of the stringer 12but may be configured to facilitate the drilling of holes in the panel26 alone or in the stringer 12 alone.

As was earlier mentioned, the crawler assembly 10 may be adapted toindex from a reference feature 194 such as an index hole 196 that may bepre-drilled in an upstream process. Alternatively, the crawler assembly10 may be adapted to index from a reference feature 194 such as asurface feature (e.g., part edge or part surface) of the stringer 12and/or of the panel 26.

Referring to FIG. 9, shown are the longitudinal and lateral sliders 60,74 which cooperate to move the drill bushing 102 of the crawler assembly10 to any one of a plurality of predetermined hole locations 192. As canbe seen in FIG. 9, each one of the longitudinal and lateral sliders 60,74 may comprise a frame 62, 76 which, in one embodiment, may include ahorizontal leg 64, 78 and a pair of vertical legs 66, 80 extending fromrespective ones of the horizontal legs 64, 78. As shown in the figures,the horizontal leg 64 of the longitudinal slider 60 may extend along thestringer 12 when the crawler assembly 10 is mounted thereto. Thevertical legs 66 may extend downwardly on one or both sides of thevertical web 20 toward the lower flange 18 of the stringer 12 whereinthe vertical legs 66 on each side of the stringer 12 may beinterconnected by a base 68. The longitudinal slider 60 may be engagedto the attachment mechanism 28 along the horizontal leg 64 of the frame62. The normalizing mechanism 106 may be connected to the base 68 of thelongitudinal slider 60 on one or both sides thereof.

The frame 76 of the lateral slider 74 may comprise a pair of U-shapedmembers which may each comprise a horizontal leg 78 and a pair ofvertical legs 80 extending downwardly therefrom and being interconnectedby a base 82 of the lateral slider 74. Each one of the bases 82 of thelateral slider 74 may include one or more guide slots 84 for engaging acomplementary set of lower sliders 70 formed on the base 68 of thelongitudinal slider 60. Sliding cooperation between the guide slots 84and the lower sliders 70 stabilizes the lateral slider 74 duringmovement relative to the longitudinal slider 60.

It should be noted that the specific configuration of the lower sliders70 and guide slots 84 of the lateral and longitudinal sliders 74, 60 atthe bases 82, 68 is exemplary only and should not be construed aslimiting alternative configurations for facilitating interconnection ofthe lateral and longitudinal sliders 74, 60 at the bases 82, 68. Forexample, instead of the guide slots 84 being formed in the lateralslider 74, the guide slots 84 may be formed in the longitudinal slider60 with the lower sliders 70 being formed on the base 82 of the lateralslider 74. Additional configurations are contemplated forinterconnecting the lateral and longitudinal sliders 74, 60 at the bases82, 68 such that the illustrated configurations are not to be construedas limiting alternative embodiments.

Referring to FIG. 11, the drill bushing 102 may be mounted to each oneof the bases 82 of the lateral slider 74. Although each drill bushing102 is shown mounted on the respective bases 82 of the lateral slider74, any number of drill bushings may be provided and in any orientationand configuration. Furthermore, although the lateral slider 74 isconfigured to move in a direction that is perpendicular to a planedefined by the vertical web 20 of the stringer 12, it is furthercontemplated that the lateral slider 74 may be configured to move in adirection that is parallel to a plane defined by the vertical web 20 orin any other direction. Such orientation may facilitate the drilling ofholes in the vertical web 20 as opposed to the configuration illustratedin the figures which facilitates drilling of holes in the lower flange18 and/or panel 26.

For configurations wherein the drill bushings 102 are oriented to drillholes in the vertical web 20 of the stringer 12, the above-describedlower sliders 70 and guide slots 84 which interconnect the lateralslider 74 to the longitudinal slider 60 may be replaced by analternative interconnection mechanism facilitating relative slidingmovement of the longitudinal and lateral sliders 60, 74 along a planeparallel to the vertical web 20. It is further contemplated that thecrawler assembly 10 may be configured to facilitate movement of thelateral slider 74 in a combination of directions such as along adirection that is both perpendicular and parallel to the plane of thevertical web 20 of the stringer 12.

Each one of the longitudinal and lateral sliders 60, 74 may include atleast one drive mechanism 120 such as an electrically powered motor orother suitable drive mechanism. The drive mechanisms 120 are preferablypowered by a suitable power source 146 such as a battery which may beintegrated into the crawler assembly 10 such that the crawler assembly10 is provided as a self-contained unit. Although provided in anysuitable A.C. or D.C. arrangement, in a preferable embodiment, the powersource 146 may be configured as a lithium polymer battery havingrecharging capability and which is preferably of a low voltage and highamperage output.

The crawler assembly 10 may further comprise an appropriate drive train50 to operatively couple each one of the drive mechanisms 120 torespective ones of the longitudinal and lateral sliders 60, 74. Forexample, as best seen in FIG. 11, the drive train 50 may comprise a rack34 and pinion 122. The drive mechanism 120 for the longitudinal slider60 may include a pinion 122 gear having circumferentially arranged gearteeth 36 configured to mesh with a rack 34 (i.e., gear teeth 36) formedlinearly along a length of the rail 30 of the attachment mechanism 28.

Likewise, the drive mechanism 120 for the lateral slider 74 may includea pinion 122 gear configured to mesh with a short length of rack 34fixably mounted to the frame 76 of the lateral slider 74 as best seen inFIG. 11. The rack 34 and pinion 122 of drive train 50 of thelongitudinal slider 60 which couples the drive mechanism 120 (i.e.,motor) to the attachment mechanism 28 facilitates movement of thecrawler assembly 10 along a direction that is parallel to thelongitudinal axis 14. Likewise, the drive mechanism 120 (i.e., motor) ofthe lateral slider 74 facilitates movement of the lateral slider 74 in adirection that is perpendicular to the longitudinal axis 14.

In a preferable embodiment, the pinions of each of the drive mechanisms120 (i.e., motors) of the longitudinal and lateral sliders 60, 74 areconfigured to be disengagable from the respective racks thereof. As bestseen in FIG. 11, the disengagement feature may comprise a motor bracket124 which may be pivotally mounted to the frame 62 of the longitudinalslider 60 by means of a pivot pin 126. In this regard, each of the motorbrackets 124 for the drive mechanisms 120 of the lateral andlongitudinal sliders 74, 60 may be pivotable about the pivot pin 126 inorder to allow pivoting of the drive mechanism 120 away from the rack34.

A common pivot arm 128 may be provided for the motor brackets 124 toallow for simultaneous manual disengagement of the drive mechanisms 120(i.e., motors) of the lateral and longitudinal sliders 74, 60. At leastone and, more preferably, both of the drive mechanisms 120 may include abiasing mechanism to bias each of the drive mechanisms 120 towardengagement with the respective racks of the longitudinal and lateralsliders 60, 74. In this manner, the pinion 122 gears of each motor maybe disengaged from the racks 34 of the attachment mechanism 28 andlateral slider 74 by manually pulling on the pivot arm 128 such that thedrill bushing 102 may be manually positioned at any location.

In a further embodiment, the crawler assembly 10 may comprise at leastone brake mechanism 130 which is configured to apply a braking forceagainst movement of the crawler assembly 10. More specifically, thelongitudinal slider 60 may include at least one brake mechanism 130configured to apply a braking force against the attachment mechanism 28for stopping the drill bushing 102 at a predetermined hole location 192along the stringer 12. Likewise, a brake mechanism 130 may apply abraking force against movement of the longitudinal slider 60 to stop thelateral slider 74 at the predetermined hole locations 192. The brakemechanism 130 for the longitudinal slider 60 is configured to stopmovement of the crawler assembly 10 along the stringer 12. Conversely,the brake mechanism 130 for the lateral slider 74 is configured to stopmovement of the crawler assembly 10 in a direction that is perpendicularto the stringer 12.

The brake mechanisms 130 for the longitudinal and lateral sliders 74, 60cooperate with the drive mechanisms 120 to move the drill bushings 102to the predetermined hole locations 192 whereupon the machiningoperation (i.e., drilling) may be performed prior to moving on to asubsequent predetermined hole location 192 of the hole pattern 190. Thebrake mechanisms 130 may be provided in any suitable embodiment and,preferably, comprise an electromagnet 132 configured to magneticallyengage a metallic component of the crawler assembly 10.

As shown in FIGS. 1-4, the brake mechanisms 130 for the longitudinalslider 60 may comprise a pair of electromagnets 132 mounted on opposingends of the horizontal leg 64 of the frame 62. Each of theelectromagnets 132 is configured to magnetically engage the attachmentmechanism 28 which, in a preferable embodiment, is formed of metallicmaterial. Likewise, an electromagnet 132 may be integrally formed withat least one of the horizontal legs 78 of the frame 76 of the lateralslider 74 and may be configured to magnetically engage a metalliccomponent such as the frame 62 of the longitudinal slider 60. However, asimple spring-loaded brake may be implemented.

The crawler assembly 10 may further comprise at least one and, morepreferably, a pair of position feedback mechanisms 134 for providingfeedback regarding the position of the drill bushing 102 relative to thereference feature 194. More specifically, the position feedbackmechanisms 134 are preferably communicatively coupled to a controller148 as best seen in FIGS. 1 and 2 and which is operative to regulatemovement of the longitudinal and lateral sliders 60, 74. The controller148 preferably includes a suitable processor assembly 168 and mayinclude an operator interface 150 communicatively coupled to the drivemechanisms 120 and to the brake mechanisms 130. The controller 148 isspecifically configured to regulate operation of the drive and brakemechanisms 120, 130 in order to move the drill bushing 102 to apredetermined hole location 192.

Position feedback mechanisms 134 such as rotary or linear encoders 136may be communicatively coupled to the controllers 148 to provideposition feedback to the microprocessor for controlling operation of thedrive mechanisms 120 (i.e., motors). The controller 148 and associatedelectronics as well as the drive mechanisms 120 and the brake mechanisms130 are preferably powered by the power source 146 which, as was earlierdescribed, preferably comprises a suitable low-voltage D.C. power source146 such as a battery. The controller 148 may be preprogrammed with anumerically controlled hole pattern 190 for driving the crawler assembly10 via operation of the drive mechanism 120 and brake mechanisms 130.

Alternatively, the operator interface 150 may be adapted to permitreal-time control of the crawler assembly 10 via the controller 148 inorder to move the crawler assembly 10 to a desired hole location(s). Aswas indicated above, movement of the controller 148 may be keyed orindexed from a reference feature 194 such as a pre-drilled index hole196 in the panel 26 and/or stringer 12. However, the reference feature194 may comprise a part feature of the upper flange 16, lower flange 18,vertical web 20 or other features.

In a further embodiment, the reference feature 194 may be provided via athrough-the-skin alignment mechanism which may comprise a magnet 198configured for insertion into the drill bushing 102. As best seen inFIG. 5, a magnetic pickup 200 or magnetic sensor may be held by atechnician and may be visually aligned with a desired hole location on abackside of the panel 26. The crawler assembly 10 on an opposite side ofthe panel may be manually moved to the magnetic pickup 200 until themagnet 198 in the drill bushing 102 is magnetically aligned with themagnetic pickup 200 on the backside of the panel 26.

Regardless of the manner in which the reference feature 194 is locatedor indexed, once indexed, the drive mechanisms 120 may then bere-engaged by releasing the pivot arm 128 such that the pinion 122 gearsof the motors re-engage the respective racks 34 of the longitudinal andlateral sliders 60, 74. The crawler assembly 10 may then be activated tocause the drive mechanisms 120 and brake mechanisms 130 to move thedrill bushing 102 to a new hole location.

The controller 148 is preferably programmable with at least one holepattern 190 each comprising one or more predetermined hole locations192. The controller 148 is operative to cause the drive and brakemechanisms 120, 130 to cooperate in moving the drill bushing 102 towardat least one of the predetermined hole locations 192 in the hole pattern190 and stopping the drill bushing 102 thereat. Upon arrival at thepredetermined hole location, the desired machining operation such asmanual drilling may be performed using a drill motor. As was earliermentioned, the controller 148 is pre-programmable with a hole pattern190 or may be manually programmed with a hole pattern 190. In addition,the controller 148 may allow for manual entry of predetermined holelocation 192 coordinates in real-time.

Referring now to FIGS. 12A-22, in an alternative embodiment, shown is acrawler assembly 10 utilizing friction drive for movement along thestringer 12. In this regard, the embodiment illustrated in FIGS. 12A-22omits the attachment mechanism 28 and instead directly mounts to thestringer 12 and is frictionally engageable thereto. The crawler assembly10 illustrated in FIGS. 12A-22 may further include the drill bushing 102as described above for performing machining operations such as drillingfastener holes.

As best seen in FIG. 17, the crawler assembly 10 is directly engageableto the stringer 12 and is frictionally driven therealong by at least oneand, more preferably, a pair of drive rollers 178 which are disposablein rolling contact against the outer surface 24 of the upper flange 16of the stringer 12. Furthermore, the crawler assembly 10 may include apair of clamping devices 40 preferably disposable on opposing ends ofthe crawler assembly 10. Each one of the clamping devices 40 preferablyincludes at least one stringer roller 108 disposable in rolling contactagainst the inner surface 22 of the upper flange 16 of the stringer 12.The stringer roller 108 and the drive roller 178 cooperate to clamp theupper flange 16 therebetween. The drive roller 178 is coupled to a drivemechanism 120 such as an electric motor for driving the crawler assembly10 along the length of the stringer 12.

As illustrated in FIGS. 12B and 13, each of the clamping devices 40 maybe comprised of a pair of pivotally mounted clamp levers 42 mounted toclamp bodies 44. The clamp levers 42 are coupled to a corresponding pairof clamp arms 46 sized and configured to engage an underside of theupper flange 16 of the stringer 12. In a configuration similar to thatdescribed above with reference to the clamping devices 40 of FIGS. 1-11,the clamping devices 40 illustrated in FIGS. 12A-22 may be configuredsuch that the clamp levers 42 are coupled to cam-shaped links that maybe connected to the clamp arms 46 in order to allow the clamping devices40 to lock into place whenever the clamp levers 42 are actuated.

As shown in FIGS. 12B, 13 and 17-20, the clamping devices 40 cooperatewith the drive rollers 178 of the longitudinal friction drive 176 toengage the crawler assembly 10 to the upper flange 16 of the stringer12. In one embodiment, the drive rollers 178 are preferably coated witha high-friction coating 180 such as a urethane coating on an outercircumference thereof in order to increase frictional engagement to theupper flange 16 of the stringer 12. The clamping devices 40 may includestringer rollers 108 in both vertical and horizontal orientations asbest seen in FIG. 17 in order to engage both the inner surface 22 of theupper flange 16 and opposing sides of the vertical web 20 of thestringer 12. As shown in FIGS. 12B and 13, the stringer rollers 108 maybe mounted on a roller bracket 110 which may extend between the opposingclamping devices 40 of the crawler assembly 10. However, it iscontemplated that the stringer rollers 108 may be provided as individualcomponents of separate clamping devices 40.

The stringer rollers 108 which bear against the opposing web surfacesmay comprise the normalizing mechanism 106 for the crawler assembly 10of FIGS. 12A-22. In this regard, the stringer rollers 108 may maintainvertical alignment of the crawler assembly 10 relative to the verticalweb 20 of the stringer 12 or other feature of the stringer 12. Thenormalizing mechanism 106 for the crawler assembly 10 illustrated inFIGS. 12A-22 is functionally similar to that which was described withreference to the normalizing mechanism 106 for the crawler assembly 10of FIGS. 1-11.

Referring to FIGS. 13 and 16-19, the stringer rollers 108 are disposablein rolling contact against at least one of the opposing sides of thevertical web 20 and may include a biasing mechanism 112 such that thestringer rollers 108 may accommodate different thickness of the verticalweb 20. The biasing mechanism 112 may comprise a compression springmounted on a threaded stud extending between a floating bracket and thearm upon which the stringer rollers 108 are mounted. Such compressionsprings may provide a self-adjustment feature for accommodatingvariations in thickness of the vertical web 20 of the stringer 12 as thecrawler assembly 10 moves therealong. The combination of the clampingdevices 40 and the drive rollers 178 facilitates mounting of the crawlerassembly 10 at any position along a length of the stringer 12. Forexample, FIGS. 14A and 16 illustrates the crawler assembly 10 beingmounted on the stringer 12 and further illustrates a plurality of holesdrilled in the vertical web 20 with the aid of the crawler assembly 10.

In a broad sense, the crawler assembly 10 of FIGS. 12A-22 is comprisedof the longitudinal friction drive 176 and the lateral slider 74. Thelongitudinal friction drive 176 is operative to move the crawlerassembly 10 in a direction that is parallel to the longitudinal axis 14of the stringer 12. The lateral slider 74 is mountable on thelongitudinal friction drive 176 and is movable in a direction that isperpendicular to the longitudinal axis 14. The lateral slider 74 mayinclude at least one drill bushing 102 described above. The longitudinalfriction drive 176 and the lateral slider 74 cooperate to move the drillbushing 102 to a desired or predetermined hole location 192 such asaccording to a CNC hole pattern 190 or via manually-inputted holecoordinates.

The lateral slider 74 is illustrated in the figures as being attached toor integral with the longitudinal friction drive 176 and is oriented insuch a manner to allow drilling of holes in the vertical web 20 of thestringer 12. However, the illustrated configuration of the lateralslider 74 is exemplary in nature and should not be construed as limitingalterative arrangements of the lateral slider 74. In this regard, it iscontemplated that the lateral slider 74 illustrated in FIGS. 12A-15 maybe substituted with a configuration of the lateral slider 74 illustratedin FIGS. 1-11 as described above.

For example, as shown in FIG. 14B, the lateral slider 74 may beconfigured to move in a direction that is perpendicular to a planedefined by the vertical web 20 of the stringer 12. One or more drillbushings 102 may be mounted to one or more bases 82. Each one of thebases 82 may be mounted to a corresponding one of the vertical legs 80of the frame 76 of the lateral slider 74. The configuration of thelateral slider 74 as shown in FIG. 14B is exemplary only and may beprovided in a variety of alternative shapes, sizes and configurations.Furthermore, the fixture(s) as mounted to the bases 82 may be providedin any number of different orientations to facilitate drilling of holesin any orientation through any portion of the stringer 12 and/or panel26. Preferably, the biasing mechanism 112 may be included in the lateralslider 74 to facilitate upward biasing of the base 82 away from thepanel 26 and stringer 12. In this manner, the lateral slider 74 may bepositioned at any location along the stringer 12 without contact betweenthe base 82 and the stringer 12 during such movement.

Referring to FIGS. 12A-14A and 16, the lateral slider 74, in oneembodiment, can be seen as comprising a pair of links 90 in afour-bar-linkage arrangement. The links 90 may be operatively coupled tothe drive mechanism 120 (i.e., motor). A fixture mounting bracket 94 maybe mounted to the links 90. The drill bushing 102 may be mounted to thefixture mounting bracket 94. The fixture mounting bracket 94 may besupported at opposing ends by at least one and, more preferably, a pairof idler rollers 92 to facilitate rolling movement of the lateral slider74 along the vertical web 20. The idler rollers 92 may provide anormalizing feature to orient the drill bushing 102 in a perpendicularorientation relative to the vertical web 20 through which the holes maybe drilled.

One of the links 90 of the lateral slider 74 may be coupled to the drivemechanism 120 (i.e., motor) by means of a threaded nut coupled to arotatable threaded shaft 88 extending outwardly from the drivemechanism. Rotation of the threaded shaft 88 causes axial movementrelative to the threaded shaft 88 and changes the position of thefixture mounting bracket 94 upon which at least one drill bushing 102 ismounted. Although the links 90 are coupled to the drive mechanism 120 bya means of the threaded nut/threaded shaft arrangement, alternativecoupling means may be implemented such as rack 34 and pinion 122 drivetrain 50 arrangement described above.

In an embodiment not shown, the lateral slider 74 may be disengagablefrom the drive mechanism 120 as described above in order to facilitatemanual movement to a different location. In this regard, a biasingmechanism 112 may be integrated into the coupling between the drivemechanism 120 (i.e., motor) and the lateral slider 74. In an alternativeembodiment not shown, the lateral slider 74 of FIGS. 12-22 may beconfigured similar to that which is illustrated in FIGS. 1-11 whereinthe lateral slider 74 includes a frame 76 having a horizontal leg 78 anda pair of vertical legs 80 extending downwardly therefrom on oppositesides of the stringer 12 with drill bushings 102 being mounted to thebases 82.

The brake mechanism 130 may be included with the lateral slider 74 tostop movement of the lateral slider 74 upon arrival of the predeterminedhole location. The lateral slider 74 may include a position feedbackmechanism 134 which may be communicatively coupled to the controller 148and which may be operative to indicate the position of the drill bushing102 along a direction perpendicular to the longitudinal axis 14 of thestringer 12. In a preferable embodiment, the position feedback mechanism134 is configured as a linear encoder 136 and may be mounted on thelateral slider 74 to provide signals indicative of the position thereof.

Likewise, and referring to FIGS. 13 and 21, the crawler assembly 10 mayfurther comprise a position feedback mechanism 134 which may becommunicatively coupled to the controller 148 for indicating theposition of the crawler assembly 10 along the longitudinal axis 14. Inone embodiment, the position feedback mechanism 134 may be integratedinto the longitudinal friction drive 176 and may be configured as arotary encoder 136 or wheel which is mounted on the longitudinalfriction drive 176 and which is operative to indicate the positionthereof relative to the stringer 12 along the longitudinal axis 14. Therotary encoder 136 preferably operates independent of the drive rollers178 to facilitate accuracy in positioning the drill bushing 102.

The longitudinal friction drive 176 may further include at least onebrake mechanism 130 (not shown) configured to apply a braking forceagainst the stringer 12 for stopping movement of the crawler assembly 10along the stringer 12. The brake mechanism 130 for the longitudinalfriction drive 176 may comprise an electromagnet 132 for magneticallyengaging the stringer 12. However, in a preferable embodiment, the brakemechanism 130 is omitted from the longitudinal friction drive 176 assuch braking force is inherently provided by operation of the drivemechanism 120 (i.e., motor) which is directly coupled to the driveroller 178. In this regard, the drive mechanism 120 acts as both adriving force and a braking force for the longitudinal friction drive176.

As best seen in FIGS. 12A-15 and 21-22, the controller 148, drivemechanisms 120, position feedback mechanisms 134 (i.e., encoder) andpower source 146, among other components, may be integrated into anelectronics module 140. The drive rollers 178 are preferably mounted inthe electronics module 140 such that a portion of each of the driverollers 178 protrudes out of wheel openings formed in an inner moduleframe 152 of the electronics module 140. Each of the drive rollers 178may be fixedly mounted to an inner module frame 152 of the electronicsmodule 140 and may be supported by a pair of bearing blocks 188 as bestseen in FIG. 21.

Each of the drive rollers 178 may be operatively coupled to a drivemechanism 120 (i.e., electric motor) by means of a gear box such as aplanetary gear motor 182 having a desired gearing ratio. The drivewheels and planetary gear motor 182 may extend through the bearingblocks 188 for supporting the drive rollers 178 that may be mounted on ashaft extending outwardly from the planetary gear motor. The innermodule frame 152 and components mounted thereto may be sandwichedbetween a lower frame 160 and an electronics module cover 156 as bestseen in FIGS. 21 and 22. The power source 146 may be configured as theabove-described battery which may be integrated into the electronicsmodule 140 via a battery opening. The controller 148 may be integratedinto the electronics module 140 and may include the necessary processorsand speed controllers 174 for regulating operation of the crawlerassembly 10. In addition, the electronics module 140 may includehardware for facilitating internet and other connectivity for remotemonitoring and/or programming of the crawler assembly 10.

As was earlier mentioned, the controller 148 is preferably adapted tofacilitate programming thereof or downloading thereto via appropriateserial ports or other connections. Furthermore, the processor assembly168 is preferably adapted to learn a specific hole pattern 190 using apolymeric sheet (e.g., Mylar—not shown) having the desired hole pattern190 formed therein. The polymeric sheet (e.g., Mylar) may be overlaid onthe stringer 12 and/or panel 26 after which the crawler assembly 10 maybe manually indexed to each location in the hole pattern 190 for storingthe hole pattern 190 for later implementation. The controller 148 mayalso be operative to download hole patterns via an Ethernet cable.

Referring still to FIGS. 21-22, the electronics module 140 cover mayinclude a top main plate 154 cover for enclosing the components withinthe electronics module 140. The top main plate 154 cover may include adisplay 162 visible through a display window 164 for displaying thevarious settings and adjustable features of the crawler assembly 10.Furthermore, the display window 164 may comprise an operator interface150 such as a keypad, pushbuttons and/or a touch screen for manuallyprogramming and/or controlling the operation of the crawler assembly 10.The electronics module 140 may include a handle 186 integrally formedinto the lower frame 160 or into other portions of the electronicsmodule 140 to facilitate positioning and transporting of the crawlerassembly 10.

Operation of the crawler assembly 10 as illustrated in FIGS. 1-11 willnow be described. In use, the elongate attachment mechanism 28 (i.e.,rail 30) may be clamped to the upper flange 16 of the stringer 12 usingthe pair of clamping devices 40 illustrated in FIGS. 1-3. The opposingclamp levers 42 for each of the clamping devices 40 may be pivotallyactuated into the downward position in order to force the clamping armsagainst an inner surface 22 of the upper flange 16 such that theattachment mechanism 28 is rigidly secured to the stringer 12.

Once the attachment mechanism 28 and the crawler assembly 10 areinstalled on the stringer 12, the normalizing mechanisms 106 may beinstalled. In the embodiment illustrated in FIGS. 1-11, the normalizingmechanisms 106 may comprise an opposing pair of stringer rollers 108disposed on opposite sides of the vertical web 20 of the stringer 12.The stringer rollers 108 may be biased into position via a biasingmechanism 112 such as a compression spring that may be included inroller brackets 110 that support the stringer rollers 108. As shown inFIGS. 3, 5 and 11, a locking pin 114 may be inserted into the rollerbrackets 110 for maintaining the position thereof relative to thelongitudinal slider 60. The biasing mechanism 112 may comprise acompression spring integrated into one or more of the roller brackets110 for providing a normalizing force for maintaining a perpendicularorientation of the crawler assembly 10 relative to the stringer 12.

Referring still to FIGS. 1-11, using a hole pattern 190 and indexingfrom a reference feature 194 such as a pre-drilled hole or a surfacefeature, the drive mechanisms 120 (i.e., motors) of the longitudinal andlateral sliders 60, 74 are caused to move to a predetermined holelocation 192 in response to control signals transmitted by thecontroller 148. As best seen in FIGS. 1, 2 and 4, the drive mechanisms120 may be operatively coupled to the longitudinal and lateral sliders60, 74 via an appropriate drive train 50 such as the rack 34 and pinion122 and may cause the crawler assembly 10 to move the drill bushing 102to the predetermined hole location 192 based on the reference feature194. The brake mechanisms 130 for the longitudinal and lateral sliders60, 74 provide a braking force to stop the drill bushing 102 at thepredetermined hole location. Position feedback mechanisms 134 such aslinear encoders 136 operatively coupled to the longitudinal and lateralsliders 60, 74 may provide information regarding the position of thedrill bushing 102 to the controller 148 and may provide error-sensingfeedback to the controller 148 to correct for errors (e.g., overshoot)in movement of the crawler assembly 10.

Once at the predetermined hole location, the operator may drill a holeusing the drill bushing 102 as shown in FIG. 11. However, any number ofa variety of machining operations may be performed. Following drillingof the hole at the predetermined hole location, the operator mayindicate via the operator interface 150 that the crawler assembly 10 canbe moved to the next predetermined hole location 192 of the hole pattern190. The procedure may be repeated until the crawler assembly 10 movesto every location in the hole pattern 190.

Operation of the crawler assembly 10 as illustrated in FIGS. 12A-22 willnow be described. The longitudinal friction drive 176 of the crawlerassembly 10 may be mounted directly on the stringer 12 by first engagingthe clamping devices 40 thereto. More specifically, the opposed pair ofclamp levers 42 may be rotated or pivoted downwardly to cause the clamparms 46 to engage an underside of the stringer 12.

As best seen in FIG. 13, the clamping device 40 may include the pair ofclamping arms 40 each having at least one stringer roller 108 that isplaced in bearing contact against opposing web surfaces of the stringer12 for clamping the vertical web 20 between the stringer roller 108. Thelongitudinal friction drive 176 preferably includes a pair of the driverollers 178 which are directly engageable to an outer surface 24 of theupper flange 16 of the stringer 12. The drive rollers 178 are disposablein rolling contact against the outer surface 24 of the stringer 12. Oneor more stringer rollers 108 are placed in bearing contact with theinner surface 22 of the stringer 12 when the clamp levers 42 areactuated. The stringer rollers 108 and drive rollers 178 are therebyclamped to the upper flange 16 such that the drive rollers 178 aremaintained in constant contact with the upper flange 16.

As can be seen in FIG. 12A-14A, the longitudinal friction drive 176 mayinclude a pair of torque knobs 142 which allow for adjustment of theheight of the drive wheels to accommodate varying thicknesses in upperflange 16. In addition, the torque knobs 142 may include a biasingmechanism such as a compression spring 144 to facilitate adjustment ofthe clamping force against the upper flange 16. The torque knobs 142 mayinclude bushings 54 which are insertable into bores 52 formed in theclamp bodies 44 as best seen in FIG. 12B.

The lateral slider 74 may optionally include a brake mechanism 130 tostop movement of the drill bushing 102 at the predetermined holelocation. The drive rollers 178 of the longitudinal friction drive 176may be directly coupled to the drive mechanism 120 or may pass through agear box assembly for altering the rotational ratio of the drivemechanism 120 relative to the drive roller 178. The drive mechanism 120of the lateral slider 74 may be operatively coupled to the fixturemounting bracket 94 for repositioning thereof. A brake mechanism 130 maybe provided to apply a braking force as the drill bushing 102 arrives atthe predetermined hole location.

Once the crawler assembly 10 is stopped at the predetermined holelocation, a desired machining operation such as drilling a fastener holemay be performed using a drill motor 104 inserted into the drill bushing102. Upon completion of the machining operation, the operator may usethe operator interface 150 to prompt the controller 148 to move thedrill bushing 102 to the next predetermined hole location 192.

Referring to FIGS. 23-24, embodiments of the disclosure may be describedin the context of an aircraft manufacturing and service method 300 asshown in FIG. 23 and an aircraft 302 as shown in FIG. 24. Duringpre-production, exemplary method 300 may include specification anddesign 304 of the aircraft 302 and material procurement 306. Duringproduction, component and subassembly manufacturing 308 and systemintegration 310 of the aircraft 302 takes place. Thereafter, theaircraft 302 may go through certification and delivery 312 in order tobe placed in service 314. While in service by a customer, the aircraft302 is scheduled for routine maintenance and service 316 (which may alsoinclude modification, reconfiguration, refurbishment, and so on).

Each of the processes of method 300 may be performed or carried out by asystem integrator, a third party, and/or an operator (e.g., a customer).For the purposes of this description, a system integrator may includewithout limitation any number of aircraft manufacturers and major-systemsubcontractors; a third party may include without limitation any numberof venders, subcontractors, and suppliers; and an operator may be anairline, leasing company, military entity, service organization, and soon.

As shown in FIG. 24, the aircraft 302 produced by exemplary method 300may include an airframe 318 with a plurality of systems 320 and aninterior 322. Examples of high-level systems 320 include one or more ofa propulsion system 324, an electrical system 326, a hydraulic system328, and an environmental system 330. Any number of other systems may beincluded. Although an aerospace example is shown, the principles of thedisclosed embodiments may be applied to other industries, such as theautomotive industry.

Apparatus and methods embodied herein may be employed during any one ormore of the stages of the production and service method 300. Forexample, components or subassemblies corresponding to production process308 may be fabricated or manufactured in a manner similar to componentsor subassemblies produced while the aircraft 302 is in service. Also,one or more apparatus embodiments, method embodiments, or a combinationthereof may be utilized during the production stages 308 and 310, forexample, by substantially expediting assembly of or reducing the cost ofan aircraft 302. Similarly, one or more of apparatus embodiments, methodembodiments, or a combination thereof may be utilized while the aircraft302 is in service, for example and without limitation, to maintenanceand service 316.

Additional modifications and improvements of the present disclosure maybe apparent to those of ordinary skill in the art. Thus, the particularcombination of parts described and illustrated herein is intended torepresent only certain embodiments of the present disclosure and is notintended to serve as limitations of alternative embodiments or deviceswithin the spirit and scope of the disclosure.

1. A crawler assembly engageable to a stringer having a vertical web anda longitudinal axis, comprising: an attachment mechanism removablyattachable to the stringer; a longitudinal slider engageable to theattachment mechanism and having a normalizing mechanism disposable inbearing contact against the vertical web for maintaining an orientationof the longitudinal slider relative to the stringer, the longitudinalslider being operative to move in a direction parallel to thelongitudinal axis; and a lateral slider mountable to the longitudinalslider and being movable in a direction perpendicular to thelongitudinal axis, the lateral slider having a drill bushing mountablethereon; wherein: the longitudinal and lateral sliders cooperate to movethe drill bushing to at least one predetermined hole location.
 2. Thecrawler assembly of claim 1 wherein: the longitudinal slider has atleast one clamping device for clamping the attachment mechanism to thestringer.
 3. The crawler assembly of claim 1 wherein: each one of thelongitudinal and lateral sliders includes at least one drive mechanism.4. The crawler assembly of claim 3 further comprising: a controllerconfigured to cause the drive mechanism to move the drill bushing towardthe predetermined hole location.
 5. The crawler assembly of claim 4wherein: the controller is operative to index the drill bushing to areference feature and cause the longitudinal and lateral sliders to movethe drill bushing from the reference feature toward the predeterminedhole location.
 6. The crawler assembly of claim 1 wherein: the lateralslider is configured to move in a direction parallel to a plane definedby the vertical web and in a direction perpendicular to the longitudinalaxis.
 7. The crawler assembly of claim 1 wherein: the lateral slider isconfigured to move in a direction perpendicular to a plane defined bythe vertical web and in a direction perpendicular to the longitudinalaxis.
 8. The crawler assembly of claim 1 further comprising: anormalizing mechanism for maintaining the crawler assembly into apredetermined orientation relative to the stringer.
 9. The crawlerassembly of claim 8 wherein: the normalizing mechanism comprises a pairof stringer rollers disposed on opposing sides of the vertical web. 10.A crawler assembly engageable to a stringer having a longitudinal axis,comprising: a longitudinal friction drive having at least one driveroller disposable in rolling contact with the stringer and beingoperative to frictionally drive the crawler assembly along a directionparallel to the longitudinal axis; and a lateral slider mountable on thelongitudinal slider and being movable in a direction perpendicular tothe longitudinal axis, the lateral slider having a drill bushingmountable thereon; wherein: the longitudinal and lateral sliderscooperate to move the drill bushing to at least one predetermined holelocation.
 11. The crawler assembly of claim 10 wherein: the longitudinalfriction drive includes at least one clamping device for clamping thecrawler assembly to the stringer.
 12. The crawler assembly of claim 11wherein: the stringer includes at least one flange having inner andouter surfaces; the drive roller being disposable in rolling contactagainst the outer surface; the clamping device having at least onestringer roller disposable in rolling contact against the inner surfacefor clamping the flange between the stringer roller and the driveroller.
 13. The crawler assembly of claim 12 wherein: at least one ofthe stringer rollers includes a biasing mechanism for biasing thestringer roller against the vertical web.
 14. The crawler assembly ofclaim 10 wherein: the stringer includes a vertical web; the clampingdevice including a pair of clamping arms each having at least onestringer roller disposable in rolling contact against opposing sides ofthe vertical web for clamping the vertical web therebetween.
 15. Thecrawler assembly of claim 10 wherein: at least one of the longitudinalfriction drive and lateral slider including a drive mechanism.
 16. Thecrawler assembly of claim 15 further comprising: a controllercommunicatively coupled to the drive mechanism and being configured tocause the drive mechanism to move the drill bushing toward thepredetermined hole location.
 17. A method of positioning a drill bushingat a predetermined hole location along a stringer, the method comprisingthe steps of: providing a crawler assembly having a normalizingmechanism and an attachment mechanism, the drill bushing being disposedon the crawler assembly; mounting the attachment mechanism to thestringer; mounting the crawler assembly to the attachment mechanism;placing the normalizing mechanism into contact with the stringer suchthat the crawler assembly is maintained in a predetermined orientationrelative to the stringer; and driving the crawler assembly along theattachment mechanism such that the drill bushing is moved toward thepredetermined hole location.
 18. The method of claim 17 furthercomprising the steps of: indexing the drill bushing to a referencefeature; and driving the crawler assembly toward the predetermined holelocation based upon the reference feature.
 19. A method of positioning adrill bushing at a predetermined hole location along a stringer, themethod comprising the steps of: providing a crawler assembly having adrive roller, the drill bushing being disposed on the crawler assembly;mounting the crawler assembly to the stringer such that the drive rolleris frictionally engaged to the stringer; and driving the crawlerassembly along the stringer using the drive roller such that the drillbushing is moved toward the predetermined hole location.
 20. The methodof claim 19 further comprising the steps of: indexing the drill bushingto a reference feature; and driving the crawler assembly toward thepredetermined hole location based upon the reference feature.